With the rails open, I went back to original steel and got everything clean and ready to accept inner plates.
Unlike my previous effort, I designed this to be fully formed at the laser shop - no assembly required. Just careful measurement, and loading the design into the sheetmetal module in bend tech.
Dimpled, cleco'd with still a bit of fine fitting to do
50 welds per flange per side, welded, individually air quenched
Still straight
David